U.S. patent application number 12/366607 was filed with the patent office on 2009-12-24 for high impact, moisture resistant wall panel system.
This patent application is currently assigned to Environmental Interiors, Inc.. Invention is credited to John C. Montgomery.
Application Number | 20090313928 12/366607 |
Document ID | / |
Family ID | 41429827 |
Filed Date | 2009-12-24 |
United States Patent
Application |
20090313928 |
Kind Code |
A1 |
Montgomery; John C. |
December 24, 2009 |
HIGH IMPACT, MOISTURE RESISTANT WALL PANEL SYSTEM
Abstract
A high impact, moisture resistant, wall panel system and methods
for mounting a high impact, moisture resistant wall panel to an
existing structure are disclosed herein. A high impact, moisture
resistant wall panel includes an inert substrate composed of a high
density inorganic material, wherein the substrate is dimensionally
stable, a laminate composed of a substantially rigid polymeric
material, and an adhesive for engaging the laminate to the
substrate.
Inventors: |
Montgomery; John C.; (New
Boston, NH) |
Correspondence
Address: |
GREENBERG TRAURIG LLP (LA)
2450 COLORADO AVENUE, SUITE 400E, INTELLECTUAL PROPERTY DEPARTMENT
SANTA MONICA
CA
90404
US
|
Assignee: |
Environmental Interiors,
Inc.
|
Family ID: |
41429827 |
Appl. No.: |
12/366607 |
Filed: |
February 5, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12144955 |
Jun 24, 2008 |
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12366607 |
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Current U.S.
Class: |
52/309.1 ;
52/408; 52/587.1; 52/762; 52/764; 52/787.11 |
Current CPC
Class: |
E04F 13/081 20130101;
Y10T 428/31855 20150401; E04F 13/18 20130101; Y10T 428/31935
20150401; E04F 13/083 20130101 |
Class at
Publication: |
52/309.1 ;
52/762; 52/787.11; 52/408; 52/764; 52/587.1 |
International
Class: |
E04C 2/20 20060101
E04C002/20; E04B 2/72 20060101 E04B002/72; E04B 1/38 20060101
E04B001/38; E04C 2/32 20060101 E04C002/32 |
Claims
1. A wall comprising: a structure including a first mounting, the
first mounting having a base secured to the structure and a hook; a
plurality of high impact panels, each panel including: an inert
substrate composed of a high density, dimensionally stable
inorganic material; a laminate composed of substantially rigid
polymeric material, wherein the laminate provides a finished
surface; an adhesive to secure the laminate to the substrate, and a
second mounting for mating with the first mounting, the second
mounting having a base secured to the substrate and a hook for
removably engaging with the hook of the first mounting secured to
the structure; and wherein the plurality of panels are securely
mounted adjacent to each other in a horizontal and vertical
relationship on the structure thereby to form a wall with the
finished surface exposed.
2. The wall of claim 1 wherein each panel is removable by
disengaging the hook of the first mounting from the hook of the
second mounting.
3. The wall of claim 1 wherein the structure further includes a
third mounting, the third mounting having a base secured to the
structure and a hook; and wherein each panel further includes a
fourth mounting for mating with the third mounting, the fourth
mounting having a base secured to the substrate and a hook for
removably engaging with the hook of the third mounting secured to
the structure; and wherein the base of the second mounting is
secured towards a top of each panel and wherein the base of the
fourth mounting is secured towards a bottom of each panel.
4. The wall of claim 3 wherein each panel is solely mounted to the
structure by the engagement of the hook of the first mounting with
the hook of the second mounting and the engagement of the hook of
the third mounting with the hook of the fourth mounting and wherein
the structure is without external framing elements about an edge of
each panel.
5. The wall of claim 1 wherein the panel is fire resistant without
requiring at least one fire retardant.
6. The wall of claim 1 wherein the panel is moisture resistant
without requiring an additional protective coating, layer or vapor
barrier.
7. The wall of claim 1 wherein each panel further includes: a side
edge of the laminate, wherein the side edge is substantially
perpendicular to a front face of the laminate; and a beveled
interface between the side edge and the front face, wherein the
beveled interface includes a beveled edge of the substrate that
underlies a beveled edge of the laminate.
8. The wall of claim 1 wherein the laminate seamlessly and
contiguously covers and bonds with a front face and a plurality of
side edges of the substrate.
9. The wall of claim 1 wherein the substrate is moisture resistant,
fire resistant and is dimensionally stable in response to changes
in temperature and humidity.
10. (canceled)
11. A wall comprising: a structure including a first mounting, the
first mounting having a base secured to the structure and a hook; a
plurality of high impact panels, each panel including: an inert
substrate composed of a high density inorganic material, wherein
the inorganic material is moisture resistant without requiring an
additional protective coating, layer or vapor barrier, is fire
resistant and is dimensionally stable in response to changes in
temperature and humidity; a laminate composed of substantially
rigid polymeric material, wherein the laminate provides a finished
surface; an adhesive to secure the laminate to the substrate, and a
second mounting for mating with the first mounting, the second
mounting having a base secured to the substrate and a hook for
removably engaging with the hook of the first mounting secured to
the structure; and wherein a wall with the finished surface exposed
is assembled by securely mounting the plurality of panels adjacent
to each other in a horizontal and vertical relationship on the
structure and wherein the wall can be disassembled by removing at
least one panel of the plurality of panels from the structure.
12. The wall of claim 11 wherein each panel can be disassembled by
disengaging the hook of the first mounting from the hook of the
second mounting.
13. The wall of claim 11 wherein each panel further includes: a
side edge of the laminate, wherein the side edge is substantially
perpendicular to a front face of the laminate; and a beveled
interface between the side edge and the front face, wherein the
beveled interface includes a beveled edge of the substrate that
underlies a beveled edge of the laminate.
14. The wall of claim 11 wherein the structure further includes a
third mounting, the third mounting having a base secured to the
structure and a hook; and wherein each panel further includes a
fourth mounting for mating with the third mounting, the fourth
mounting having a base secured to the substrate and a hook for
removably engaging with the hook of the third mounting secured to
the structure; and wherein the base of the second mounting is
secured towards a top of each panel and wherein the base of the
fourth mounting is secured towards a bottom of each panel.
15. The wall of claim 14 wherein each panel is solely mounted to
the structure by the engagement of the hook of the first mounting
with the hook of the second mounting, and the engagement of the
hook of the third mounting with the hook of the fourth
mounting.
16. A high impact panel for mounting on a separate structure to
form a wall, the panel comprising: an inert substrate composed of a
high density, dimensionally stable inorganic material; a laminate
composed of substantially rigid polymeric material, wherein the
laminate provides a finished surface; an adhesive to secure the
laminate to the substrate; and a first mounting on the panel, the
first mounting being for mating with a second mounting on the
structure, the first mounting having a base secured to the
substrate and a hook for removably engaging with a hook of the
second mounting, the second mounting having a base secured to the
structure, wherein the panel is capable of secure mounting on the
structure with the finished surface exposed.
17. The panel of claim 16 wherein each mounting is a device for
suspending the panel on the structure, wherein the base of the
first mounting is formed to be parallel to a rear face of the
panel, and the base of the second mounting is formed to be parallel
to the structure, and wherein the hook of the first mounting and
the hook of the second mounting is for inter-engagement to suspend
the panel from the structure and to form the wall, and wherein the
wall can be disassembled by disengaging the hook of the first
mounting from the hook of the second mounting.
18. The panel of claim 16 further comprising a third mounting for
mating with a fourth mounting of the structure, the third mounting
having a base secured to the substrate and a hook for removably
engaging with a hook of the fourth mounting secured to the
structure; and wherein the base of the first mounting is secured
towards a top of the panel and wherein the base of the third
mounting is secured towards a bottom of the panel.
19. The panel of claim 18 wherein the panel is solely mounted to
the structure by the engagement of the hook of the first mounting
with the hook of the second mounting, and the engagement of the
hook of the third mounting with the hook of the fourth
mounting.
20. A plurality of panels each panel being a panel according to
claim 16, wherein each panel is for mounting adjacent to another
panel in a horizontal and vertical relationship to form a wall.
Description
RELATED APPLICATION
[0001] This application is a Continuation of U.S. Utility
application Ser. No. 12/144,955, filed Jun. 24, 2008, still
pending, the contents of which are incorporated by reference herein
in its entirety.
BACKGROUND
[0002] 1. Field
[0003] The presently disclosed embodiments relate to wall panel
systems, and more particularly to a high impact, moisture and flame
resistant wall panel system.
[0004] 2. General Background
[0005] Existing wall panel systems suffer from design
inefficiencies that lead to expensive and time consuming panel
construction, panel repair and panel replacement. Existing wall
panel systems often use a fiberboard substrate that is composed of
organic material. Because the organic substrate is not
dimensionally stable, the substrate requires a vapor barrier.
Without a vapor barrier the organic substrate would expand upon
absorbing moisture or contract upon losing moisture when humidity
changes, thus increasing the risk of delamination of the panel
laminate, disconnection of the panels from the attachment system,
and deformation of the finished panels.
[0006] Installation of existing wall panel systems over walls
having irregular surfaces often use a construction grade adhesive.
The construction grade adhesive often used by existing wall panel
systems requires removal of multiple adjacent panels in succession
to replace a single damaged panel. Individual panels of existing
wall panel systems are often not removable without affecting
adjacent panels. The lack of substantial edge bonding of the panel
laminate to the panel substrate decreases impact resistance and
increases the risk of delamination of the laminate from the
substrate. The contours of the organic substrate also make it
difficult to vacuum form the laminate onto the substrate with
architectural detailing without imperfections in the substrate
showing on the surface finish. Thus, there is a need in the art for
a high impact, moisture resistant wall panel system made from a
dimensionally stable substrate without a vapor barrier.
SUMMARY
[0007] A high impact, moisture resistant wall panel system and
methods for mounting wall panels to an existing structure are
disclosed herein. According to aspects illustrated herein, there is
provided wall panel system that includes a plurality of panels,
each panel comprising an inert substrate composed of a high density
inorganic material, wherein the substrate is dimensionally stable,
and a laminate composed of substantially rigid polymeric material,
wherein an adhesive secures the laminate to the substrate.
[0008] According to aspects illustrated herein, there is provided a
wall panel that includes an inert substrate composed of a high
density inorganic material, wherein the substrate is dimensionally
stable, a laminate composed of a substantially rigid polymeric
material, and an adhesive for engaging the laminate to the
substrate.
[0009] According to aspects illustrated herein, there is provided a
method of mounting a high impact, water resistant panel to an
existing structure that includes providing at least one high
impact, water resistant panel having a back face and a front face,
wherein the panel has a mounting member, providing at least one
wall mount having a first end and a second end, wherein the first
end of the wall mount is secured to an existing structure, at least
one mounting member has a first end secured to the back face of the
panel, and engaging a second end of the mounting member with the
second end of each wall mount, to secure the panel to the existing
structure, wherein the panel is substantially parallel to the
existing structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The presently disclosed embodiments will be further
explained with reference to the attached drawings, wherein like
structures are referred to by like numerals throughout the several
views. The drawings shown are not necessarily to scale, with
emphasis instead generally being placed upon illustrating the
principles of the presently disclosed embodiments.
[0011] FIG. 1 is a perspective view of a wall panel system of the
presently disclosed embodiments.
[0012] FIG. 2 is a front view of a panel of the presently disclosed
embodiments.
[0013] FIG. 3 is a cross-section view of an edge portion of a
panel, taken along lines A-A of FIG. 2.
[0014] FIG. 4 is a perspective cutaway view showing the layers of a
panel.
[0015] FIG. 5 is a perspective assembly view of a wall panel system
mounted to a wall.
[0016] FIG. 6 is a cross-section view of a representative vertical
joint and adjacent panels.
[0017] FIG. 7 is a cross-section view of a representative
horizontal joint and adjacent panels.
[0018] FIG. 8 is a cross-section view of a representative joint
between a panel and a ceiling.
[0019] FIG. 9 is a cross-section view of a representative wall
panel system base between a panel and a floor.
[0020] FIG. 10 is a cross-section view of a representative
inside-corner joint and adjacent panels.
[0021] FIG. 11 is a cross-section view of a representative panel at
the end of the wall panel system.
[0022] FIG. 12 is a cross-section view of a representative
outside-corner joint.
[0023] While the above-identified drawings set forth presently
disclosed embodiments, other embodiments are also contemplated, as
noted in the discussion. This disclosure presents illustrative
embodiments by way of representation and not limitation. Numerous
other modifications and embodiments can be devised by those skilled
in the art which fall within the scope and spirit of the principles
of the presently disclosed embodiments.
DETAILED DESCRIPTION
[0024] A wall panel system with removable high impact, moisture
resistant panels that provides improved design efficiency and
confers structural advantages is disclosed herein. Structural
advantages of the panels and the wall panel system of the presently
disclosed embodiments include, but are not limited to, increased
impact resistance, moisture resistance without requiring additional
protective coatings or additional protective layers, and fire
resistance without requiring additional fire retardants. Improved
design efficiencies of the panels and the wall panel system of the
presently disclosed embodiments include, but are not limited to
simplified panel construction, panel installation, panel repair,
panel replacement, panel dimensional stability, a surface finish
laminate that can be vacuum formed for architectural detailing, and
substantial edge bonding to reduce the risk of delamination.
[0025] As used herein, the term "dimensionally stable" refers to a
material characterized by dimensions which remain constant under
normal temperatures and pressures and also remain substantially
constant with changes in temperature and humidity. A dimensionally
stable material maintains its size and shape in changing
environmental conditions. Dimensionally stable should also be
understood to mean that a material, for instance a substrate, will
not significantly distort, decompose, or change due to changes in
ambient temperature or humidity. A dimensionally stable material
absorbs or loses a negligible amount of moisture upon changes in
humidity. For example, as humidity increases a dimensionally stable
material will not substantially expand if it absorbs moisture and
as humidity decreases a dimensionally stable material will not
substantially contract when it loses moisture. Dimensionally stable
also refers to the ability of a material to remain flat upon
changes in temperature and humidity. Thus, the dimensionally stable
substrate of the presently disclosed embodiments will not
substantially warp, expand, or contract so the laminate remains
engaged to the substrate and does not detach from the
substrate.
[0026] As used herein, the term "inert" refers to a material which
does not substantially change or react upon contact with another
substance.
[0027] As used herein, the term "inorganic" refers to a material
that is substantially free of organic material. In an embodiment, a
substrate of a panel of the present disclosed embodiments comprises
inorganic material that is substantially free of organic material.
It is possible that a small amount of organic material may be
present in the inorganic material.
[0028] As used herein, the term "laminate" includes any material
that may be used as a structure that may be attached to another
structure. A laminate may comprise any composition, size, shape, or
form. In an embodiment, the laminate used to form a panel of the
presently disclosed embodiments comprises substantially rigid
polymeric material. For example, a laminate may be formed as a
thermoplastic sheet having a desired thickness and a customizable
finish.
[0029] As used herein, the term "substrate" includes any material
that may be used as structure to which another structure may be
attached onto. A substrate may comprise any composition, size,
shape, or form. In an embodiment, the substrate used to fabricate a
panel of the presently disclosed embodiments comprises a high
density, inert, inorganic material, wherein the substrate is
dimensionally stable. For example, a substrate may be fabricated as
a sheet having a desired thickness.
[0030] As shown in the perspective view of FIG. 1, an isolated wall
segment of a wall panel system 20 of the presently disclosed
embodiments, spanning from a first end 14 to a second end 17 across
an existing structure 16, comprises a plurality of panels 30 that
are configurable to form a wall system expanding beyond the
isolated wall segment displayed in FIG. 1. Typically, a wall of the
wall panel system, as shown in FIG. 1, will have panels 30 spanning
from a ceiling 19 all the way down to a base 18. Although FIG. 1
shows three pairs of adjacent side-by-side panels stacked upon each
other from a floor 15 to the ceiling 19 in vertical fashion, a wall
panel system may comprise any number of panels 30 stacked in
horizontal orientation combined with any number of panels 30
stacked in vertical orientation depending on the conditions and
requirements of a particular field site. For example, a wall panel
system 20 may require at least one or more panels 30 stacked in
vertical orientation and may also require at least one or more
panels 30 stacked in horizontal orientation across an existing
structure.
[0031] In an embodiment, a plurality of panels 30 of the presently
disclosed embodiments may be assembled to form a wall panel system
20 designed to be installed directly an existing structure 16. In
an embodiment, an existing structure 16 comprises a wall. In an
embodiment, an existing structure 16 comprises an exterior wall. In
an embodiment, an existing structure 16 comprises an interior wall.
For example, the wall panel system may be installed directly over
existing walls or over an existing foundation such as wood framing
or a concrete foundation. Additionally, the wall panel system 20
may be installed over an existing structure made of a variety of
materials. For example, the wall panel system 20 may be installed
over existing structures including, but not limited to concrete
block, brick, steel, ceramic tile, or dry wall. The wall panel
system 20 may be installed over existing structures having a
variety of surface variations, such as smooth surfaced structures
or structures having irregular surfaces and uneven geometry.
[0032] The base 18 conceals and finishes the joints where the wall
panel system meets the floor. In an embodiment, the base 18
comprises a base plate 21 (as shown in FIG. 9) and a blocking 23
(as shown in FIG. 9), wherein the blocking acts as a backer to the
base plate and provides support for and reinforces the base. In an
embodiment, the base 18 comprises a stainless steel plate 21 (as
shown in FIG. 9) and a wooden blocking 23 (as shown in FIG. 9). In
an embodiment, the base 18 comprises a sized and cut panel that is
fabricated to fit between a panel 30 and the floor 15. In an
embodiment, the base 18 comprises a series of sized and cut panels
that are fabricated to fit between a panel 30 and the floor 15
spanning from a first end 14 to a second end 17 across an existing
structure 16. The base may be composed of metal, plastic, wood,
block, brick, vinyl, or other materials known to those skilled in
the art.
[0033] FIG. 2 shows a front view of a panel 30, and a laminate 22.
In an embodiment, the laminate has at least one beveled 32 edge. In
an embodiment, each panel 30 comprises a substrate and a laminate,
wherein the laminate is secured to the substrate with an adhesive.
In an embodiment, each panel comprises an inert substrate of high
density inorganic material, wherein the substrate is dimensionally
stable; and a laminate of substantially rigid polymeric material,
wherein an adhesive secures the laminate to the substrate.
[0034] FIG. 3 shows a cross-sectional view of an edge portion of a
panel 30 taken along lines A-A of FIG. 2. In an embodiment, a panel
30 includes a substrate 24 and a laminate 22 bonded together by an
adhesive 26. In an embodiment, the panel includes an undercut edge
28 at a juncture between at least one side edge 29 of the panel and
a back face 33 of the panel. In an embodiment, the panel includes a
flange 36 extending from at least one edge of the laminate. In an
embodiment, the flange 36 is substantially perpendicular to a front
face 31 of the panel 30. In an embodiment, the panel 30 includes a
bevel 34 at a juncture between at least one side edge 35 of the
substrate and a front face 37 of the substrate. In an embodiment,
the panel includes a beveled 32 edge at a juncture between the
flange 36 and the front face of the panel 31.
[0035] The substrate 24 of the presently disclosed embodiments is
strong and durable and includes one or more of the following
characteristics: UL approved fireproof, fire resistance without
requiring additional fire retardants, ASTM rated mold proof, ASTM
rated waterproof, moisture resistant without requiring additional
protective barriers, ASTM rated insect free, ASTM rated fungus
free, interior or exterior compatible, high impact, hurricane
tested, asbestos free, silica free, or sound suppressing. The
substrate 24 may comprise inert material, inorganic material, high
density material, ultra-high-density material or dimensionally
stable material.
[0036] In an embodiment, the substrate 24 comprises inert,
inorganic, high density material, wherein the substrate is
dimensionally stable.
[0037] The substrate 24 of the presently disclosed embodiments is
inert. The substrate 24 does not substantially change or react upon
contact with another substance. An inert substrate maintains its
characteristics, size, and shape when exposed to changing
environmental conditions. Providing an inert substrate adds to the
strength, weight, and fire resistance of the substrate. To provide
panels for a wall panel system that is useful in a variety of
environments, panels should be capable of adapting to environmental
changes without warping, expanding, or contracting. The inert
substrate 24 is less likely to react in response to contact with
moisture or fire and less likely to react in response to changes in
temperature or humidity. Providing an inert substrate allows the
substrate to adapt to environmental changes and remain
dimensionally stable. Thus, the inert substrate provides for a
panel that is long lasting and durable under a variety of
conditions providing for a durable wall panel system that has a
longer-life and is subject to decreased maintenance costs over
time.
[0038] The substrate 24 of the presently disclosed embodiments is
inorganic. The inorganic substrate 24 is substantially free of
organic material. Wall panel systems require panels that comport
with public safety codes, such as fire safety, and panels that are
durable.
[0039] Organic materials are made from natural processes and may be
more flammable, subject to increased wear, and subject to
decomposition. Organic materials may not be dimensionally stable
because organic materials may absorb too much moisture as humidity
increases and may lose too much moisture as humidity decreases,
subjecting organic materials to warping, expanding or contracting
in response to environmental changes in temperature and
humidity.
[0040] Inorganic materials are composed of synthetic materials that
are less flammable, designed to be durable, and less subject to
decomposition. As humidity increases, inorganic materials will
absorb a negligible amount of moisture and as humidity decreases
inorganic materials will lose a negligible amount of water such
that the inorganic material will not substantially warp, expand,
contract, or shrink. The inorganic substrate provides for a long
lasting and durable panel that helps prevent fire spreading and
helps prevents the panel from warping, expanding or contracting,
thus decreasing the risk of delamination. In an embodiment, the
inorganic material includes recycled materials or recovered
materials.
[0041] The substrate 24 of the presently disclosed embodiments has
a high density. The density of a material determines its resistance
to wear and abrasion, its durability in use, and the costs required
to maintain it. The high density of the substrate provides a panel
with impact resistance. Higher density materials provide greater
impact resistance than materials having less density. Impact
resistance is important for wall panel systems because wall panel
systems are used in places where walls are subject to damage from
increased abuse from objects being transported about the place. The
high density substrate 24 provides a panel with impact resistance
that will be resistant to wear and abrasion, durable, and decrease
maintenance costs. The high density substrate 24 provides a panel
that can be used in a variety of places where wall panel systems
are desired. In an embodiment, the high density substrate 24 has a
density of about 50 pounds per cubic foot or greater.
[0042] The substrate 24 of the presently disclosed embodiments is
dimensionally stable. The dimensional stability of a material, as
the material responds to changes in temperature and moisture
content, affects the manner in which the material may be detailed
and constructed to combine with other materials. The dimensionally
stable substrate 24 is capable of maintaining substantially
constant dimensions with changes in temperature and humidity. The
dimensionally stable substrate 24 is less likely to significantly
distort, decompose, or change substantially due to changes in
ambient temperature and humidity. Providing a dimensionally stable
substrate 24 decreases the chances that changes in temperature and
moisture will alter the dimensions of the substrate and affect
other components of the wall panel system. Providing a
dimensionally stable substrate 24 provides for longer lasting and
more durable panels since the panels are less subject to
deformation under a variety of conditions. For example, the
dimensionally stable substrate 24 absorbs or loses a negligible
amount of water upon changes in temperature and humidity. The
dimensionally stable substrate 24 will not substantially warp,
expand, contract, or shrink. Thus, the dimensionally stable
substrate 24 will remain engaged to a laminate and the laminate
will not substantially detach from the dimensionally stable
substrate 24. The dimensionally stable substrate 24 provides a wall
panel system that has a longer-life, thus reducing maintenance and
repair costs over time.
[0043] The substrate 24 provides moisture resistance without
requiring additional protective coating or layering. Moisture
resistance aids development of long-lasting and durable panels,
which are necessary for producing long-lasting and durable wall
panel systems. If a substrate absorbs or loses too much moisture,
the laminate may detach from the substrate. The substrate 24 of the
presently disclosed embodiments prevents panel warping, expanding,
and contracting without requiring a vapor barrier. The presently
disclosed embodiments provide a high density inorganic material
that causes the substrate 24 of a panel 30 to be non-absorbing.
Moisture and water vapor are not absorbed into the panel. In an
embodiment, the substrate 24 is ASTM rated waterproof. Thus, the
presently disclosed embodiments confer panel construction
efficiencies by providing moisture resistance without requiring
additional coatings or protective layers during panel
formation.
[0044] The moisture resistant substrate 24 permits wall panel
system installation to begin before a field site under construction
is completely dry. Thus, the substrate 24 provides a panel that
confers construction efficiencies that speed up the wall panel
system installation process.
[0045] The substrate 24 provides fire resistance without requiring
compounding of additional fire retardants into the substrate. Fire
resistance is important for developing durable panels and for
developing panels that comport with public safety codes. Fire
resistance helps prevent the spread of fires. A substrate having a
prevalence of organic materials in the substrate may require the
addition of fire retardants during manufacturing of the substrate.
By providing an inorganic substrate, the requirement to add fire
retardants into the substrate during the substrate manufacturing
process is eliminated. Thus, the presently disclosed embodiments
confer panel construction efficiencies by providing fire resistance
without requiring the addition of fire retardants to the substrate
24 during panel formation.
[0046] The substrate 24 provides consistent fire resistance
throughout the entire composition of the substrate. The fire
resistance is homogenous throughout the entire substrate material,
not just coated on the outside layer of the substrate. Thus, the
homogenously fire resistant substrate 24 does not require addition
of fire-retardant coatings after field modifications, including
cutting a panel, are made to a panel.
[0047] In an embodiment, the substrate 24 is UL approved fire
proof. The substrate 24 is ASTM class A fire rated. In an
embodiment, the substrate 24 is approved for 1-hour, 11/2-hour,
2-hour, 3-hour and 4-hour fire resistant wall systems.
[0048] The substrate 24 may comprise any composition and may be
sized, shaped, and fabricated to any desired parameters. For
example, the substrate 24 may be any desired thickness, such as
1/8, 1/4, 3/8, 7/16, 9/16, 5/8, 3/4 of an inch or larger. In an
embodiment, the substrate 24 comprises a sheet. In an embodiment, a
substrate 24 sheet is prepared by forming true edges, square
corners, and the required dimensions to precisely close tolerances.
A juncture between the back face 33 and each side edge 35 of the
substrate 24 sheet is cut so as to leave an undercut 28 along each
edge. The substrate 24 sheet also contains a bevel 34 extending
between each side edge 35 and the front face 37 of the
substrate.
[0049] In an embodiment, the substrate is composed of a UL approved
fire resistant, water resistant, high-impact substrate that will
not disintegrate when immersed in water or exposed to prolonged
freezing and thawing cycles. In an embodiment, the substrate may be
composed of any combination of inorganic materials including, but
not limited to, magnesium oxide, magnesium chloride, finely
powdered stone, fine plastic fibers, polyester fibers, or other
inorganic materials known to those skilled in the art.
[0050] The laminate 22 is formulated for extreme resistance to
impact, chemicals, and cleaning agents. The laminate 22 is
engineered to be formed over components with deep recesses. The
laminate 22 seamlessly encapsulates the top and side surfaces of
routed substrates, thus diminishing the need for edge banding. In
an embodiment, the laminate 22 of the presently disclosed
embodiments may comprise one or more of the following:
thermoplastic material, polymeric material, rigid material,
substantially rigid material. In an embodiment, the 22 laminate
comprises a sheet. In an embodiment, the laminate 22 comprises a
thermoplastic sheet of substantially rigid polymeric material. In
an embodiment, the laminate sheet comprises an alloy of any
combination of one or more of the following: polyvinyl chloride,
acrylic, chlorinated polyvinyl chloride. In an embodiment, the
laminate 22 sheet includes an alloy of polyvinyl chloride and a
lesser amount of acrylic that is compounded with fire retardants
and smoke inhibitors so that it has a Class 1/A when tested
according to ASTM E-84. Processing aids, impact modifiers, heat
stabilizers, lubricants and pigments may be added to the
composition of the laminate sheet as desired.
[0051] In an embodiment, the laminate 22 sheet may have a thickness
of about 0.02 inch or greater. Those skilled in the art will
recognize that various thicknesses of the laminate sheet ranging
from about 0.02 inch to about 0.06 inch or greater are within the
spirit and scope of the presently disclosed embodiments.
[0052] In an embodiment, the laminate 22 is composed of a durable
thermoplastic alloy extruded in a range of colors, patterns,
textures, thicknesses and grade.
[0053] In an embodiment, the laminate 22 sheet is sized and shaped
and then may be vacuum-formed or thermoformed. In an embodiment,
the laminate sheet 22 may be both vacuum formed and thermoformed.
Optionally, vacuum-forming or thermoforming may produce a
right-angle flange 36 along each side edge of the laminate and a
beveled edge 32 forming a juncture between the flange 36 and a
front face 31 of the panel.
[0054] Thermoforming comprises heating a laminate to a point at
which it melts around a substrate. In an embodiment, a laminate 22
sheet is thermoformed onto a pre-cut commercially available
substrate sheet 24. Thermoforming a laminate onto a substrate
produces a very tight fit of the laminate to the substrate.
Typically, an adhesive is applied to the substrate before the
substrate and laminate are placed into an oven to facilitate
attachment of the laminate to the substrate. Thermoforming is
suited for producing a finished surface on the laminate comprising
the shape over which the laminate is melted onto as textured
surfaces produced on the finished faces of a laminate are limited
to those textures inherent to the laminate materials. The thicker
the laminate, the less customizable finishes can be produced with
thermoforming as thermoforming is not well suited to produce
smaller textures and detailed patterns.
[0055] Vacuum forming comprises a reverse mold into which a
laminate is heated and melted into. The mold has tiny holes in
which air is pulled through to the laminate to create a vacuum
suction of the laminate into the mold. During cooling, an adhesive
is applied to a substrate backer that is pressed into the underside
of the laminate while the laminate is still in the mold. Melting
the laminate into a reverse mold in this manner enables the
laminate to acquire the shape and detailed texturing of the mold.
The level of detail of laminate finishes produced by vacuum forming
is not limited by the thickness of the laminate. Thus, vacuum
forming can provide more detailed surface textures and designs than
thermoforming.
[0056] Vacuum forming provides for a customizable finish that
permits a variety of surface applications comprising numerous
patterns and textures applicable to laminates of a wide range of
thicknesses. In an embodiment, a panel 30 comprising a laminate 22
bonded with an adhesive 26 to a substrate 24 has a customizable
finish. The customizable finish can be a variety of embodiments,
such as textured or patterned. The technology for vacuum-forming or
thermoforming thermoplastic sheets is known in the art, as are the
techniques for making molds by replicating naturally occurring
textures (e.g., wood grain, leather, stucco, or similar textures)
or specially created textures and designs. A customizable finish
may be used to portray corporate identity.
[0057] In an embodiment, a preformed laminate 22 is bonded with an
adhesive 26 to a sized substrate 24. The adhesive assists in
creating a strong, durable bond between the laminate 22 and the
pre-cut substrate 24. The adhesive 26 is selected for compatibility
with the polymers of the laminate 22 and the composition of the
substrate 24. The adhesive 26 can also be selected for flame
resistance and smoke resistance according to a Class 1 Fire Rating
(ASTM-E84-87A). In an embodiment, the adhesive is a
non-water-soluble adhesive. In an embodiment, the adhesive
comprises glue. In an embodiment, the adhesive comprises a
contact-based adhesive. In an embodiment, the adhesive requires a
catalyst. In an embodiment, the adhesive does not require a
catalyst. In an embodiment, the adhesive comprises a vapor
resistant adhesive.
[0058] In an embodiment, the laminate 22 may contiguously engage
the entire front face 37 and may contiguously engage a plurality of
side edges 35 of the substrate 24. In an embodiment, the flange 36
and the beveled edge 32 of the laminate 22 are not bonded to the
substrate 24. In an embodiment, as FIG. 3 shows, the flange 36 and
the beveled edge 32 of the laminate 22 sheet are contiguously
bonded to the substrate 24 sheet along a plurality of the side
edges 35 of the substrate 24 sheet. In an embodiment, the flange
and beveled edge of the laminate may be completely bonded to the
substrate sheet along at least one of the side edges of the
substrate sheet or the flange and beveled edge of the laminate
sheet may be partially bonded to or not bonded at all to the
substrate sheet along at least one of the side edges of the
substrate sheet.
[0059] Bonding the flange 36 to the side edge 35 of the substrate
24 ("edge bonding") in this manner provides for maximum adhesion
between the laminate and the underlying substrate resulting in
increased impact and moisture resistance. By bonding continuously
between the laminate and the substrate fully throughout the front
face and substantially throughout a plurality of sides of the
panel, the bond is strengthened and the likelihood of detachment of
the laminate is decreased, thus improving panel durability and
impact resistance. Edge bonding may provide additional moisture
resistance by removing space between the laminate and the substrate
near the edges where moisture resulting from changes in ambient
humidity is likely to seep in. Edge bonding seals the laminate to
the substrate sides preventing moisture from getting between the
laminate and substrate. Thus, edge bonding decreases the potential
for detachment of the laminate from the substrate and provides a
dimensionally stable panel that has increased impact
resistance.
[0060] FIG. 4 shows a perspective view of a panel 30 having its
front face 31 cutaway to reveal the layers of the laminate 22, the
substrate 24, and the adhesive 26. A panel 30 is customizable
according to required design parameters.
[0061] A method of making a panel is disclosed herein. For example,
fabrication drawings of the substrate and requisite mold drawing
requirements based upon panel size requirements are produced. In an
embodiment, the substrate comprises a backer board. Once parameters
for the substrate and mold requirements are complete, the reverse
mold components for vacuum forming are fabricated. The substrate is
then cut to the specified shapes and sizes as required on a
computer numerically controlled router. Simultaneously, pilot holes
to guide field attachment of the mounting members 38 are
predrilled. In an embodiment multiple panels are nested. For
example, multiple panels are cut out of the same substrate sheet or
backer board sheet at the same time. To further facilitate panel
manufacture, as many molds as will fit on a given vacuum table are
loaded onto the vacuum table at the same time. The laminate is then
stretched across the molds and then heated. As the laminate
softens, the vacuum from the vacuum table suctions the melted
laminate into the molds. The molds comprise various designs
according to the fabrication drawings. The mold assemblies are then
removed from the vacuum table after a fixed time interval,
depending on the thickness of the laminate to be adhered to the
substrate, and put onto a table to be cooled. While the laminate is
cooling, the adhesive is applied to the substrate and the substrate
pressed into the underside of the molded laminate. Pressing the
substrate into the laminate while the laminate is cooling provides
a precision fit between the substrate and laminate, thus
facilitating approximately complete bonding at the perimeter of the
panels. Thus, no loose edges remain at the perimeter of the
finished panels further facilitating a dimensionally stable panel
that is impact resistant and is moisture resistant.
[0062] Those skilled in the art will recognize that the substrate
may be cut to the specified shapes and sizes using a computer
numerically controlled router, a hand router, a table saw, a wall
saw, a dado blade, or similar cutting devices known to those
skilled in the art. After the substrate is cut, pilot holes to
guide field attachment of the mounting members 38 are drilled into
the substrate.
[0063] A method for fabricating a panel 30 includes providing a
substrate 24; and securing a laminate 22 to the substrate with an
adhesive 26. In an embodiment, a method for fabricating a panel
includes providing an inert substrate of high density inorganic
material, wherein the substrate is dimensionally stable; and
providing a laminate of substantially rigid polymeric material,
wherein an adhesive secures the laminate to the substrate. In an
embodiment, a method for fabricating a panel includes providing an
inert substrate of high density inorganic material, wherein the
substrate is dimensionally stable; providing a laminate of
substantially rigid polymeric material, vacuum forming the laminate
onto the substrate, wherein an adhesive is first applied to the
substrate, wherein the laminate contiguously engages a front face
and a plurality of side edges of the substrate. In an embodiment, a
method for fabricating a panel includes providing a substrate,
wherein the substrate is cut on a router according to panel size
requirements; placing at least one mold onto a vacuum table,
wherein the mold is fashioned to provide a customizable finish;
stretching a laminate across the molds, wherein the laminate is
heated; suctioning the laminate into the mold, wherein the
suctioning is provided by a vacuum; removing the mold from the
vacuum table; wherein the mold may cool; applying an adhesive to
the substrate; pressing the substrate into the underside of the
molded laminate.
[0064] A panel 30 may have various dimensions. Panels 30 are
produced in sizes up to 4.times.10 feet, and beveled and undercut
edges are formed along all sides. In an embodiment, a panel with
4.times.10 feet dimensions is provided. In an embodiment, a panel
with 4.times.9 feet dimensions is provided. In an embodiment, a
panel with 4.times.8 feet dimensions is provided. As required,
parts or all of at least one of the edges may be trimmed away in
sizing and shaping a final panel for installation.
[0065] The undercut edge 28 has a depth not less than, and
preferably approximately equal to, the length necessary to
accommodate a mounting system. Specific members of the mounting
system for which the undercut portion can be cut to accommodate
include, but are not limited to corner members, brackets or
moldings, end brackets or moldings, base, base brackets or
moldings, wall mounts or mounting members, shims, end members,
corner members, inside corner guards, outside corner guards, or
extrusions. Mounting members or wall mounts may include, but are
not limited to clips, brackets, screws, connectors, or extrusions.
Those of skill in the art will recognize the various types of
extrusions that may be used within the spirit and scope of the
presently disclosed embodiments.
[0066] In an embodiment, the mounting member 38 comprises a clip.
In an embodiment, the mounting member 38 comprises a mounting clip.
In an embodiment, the mounting member 38 comprises a z-clip. In an
embodiment, the mounting member 38 comprises a 2 inch wide clip
that is twenty-four inches on center. In an embodiment, the
mounting member 38 comprises a 2 inch wide mounting z-clip that is
twenty-four inches on center. In an embodiment, the mounting member
38 is a clip that is fastened to the substrate on one end and
fastened to the wall mount 40 (as shown in FIG. 5) on the other
end. In an embodiment, the mounting member 38 is a z-clip that
engages the wall mount 40 (as shown in FIG. 5). In an embodiment,
the mounting member 38 is a z-clip that mates with the wall mount
40 shown in FIG. 5.
[0067] As shown in FIG. 5, each wall panel 30 is installed over an
existing structure 16. In an embodiment, each panel is installed
over the existing structure using a mounting system that is
integrated seamlessly with a plurality of vertical reveals 44 and a
plurality horizontal reveals 46. In an embodiment, a plurality of
vertical reveals 44 overlay a plurality of horizontal reveals 46.
In an embodiment, a plurality of horizontal reveals 46 overlay a
plurality of vertical reveals 44. In an embodiment, a plurality of
vertical reveals 44 overlay a plurality of horizontal reveals 46
and a plurality of horizontal reveals 46 overlay a plurality of
vertical reveals 44. For example, vertical reveals may overlay
horizontal reveals between panels and horizontal reveals may
overlay vertical reveals between a panel and a door or at the end
of a wall of the wall panel system.
[0068] In an embodiment, the mounting system comprises a plurality
of mounting members 38 (as shown in FIG. 4) and a plurality of wall
mounts 40 (as shown in FIG. 5). Each mounting member engages a wall
mount to form a secure, flexible lock. The secure flexible lock
formed by engaging a mounting member with a wall mount provides for
a modular wall panel system with removable panels. In an
embodiment, each panel of the wall panel system is removable. Upon
engaging each mounting member to each wall mount, the panels are
secured to the existing structure to form a stable, high impact
resistant wall system comprising a plurality of high impact
resistant wall panels. The high impact wall panels are resistant to
superficial cracking, hairline cracking, complete penetration, or
similar damage. The high impact resistant wall panels disclosed
herein are useful in a variety of commercial applications where
walls are subject to an increased risk of damage from abuse. In
such environments, abuse may damage a panel beyond repair, thus
requiring replacement of a panel. The modular, removable panel
system disclosed herein provides for the instant removal of a
single panel for repair or replacement rather than requiring
removal of additional panels adjacent to the damaged panel.
[0069] Wall panel systems using construction grade adhesives to
secure panels to underlying walls require progressive panel removal
where each panel in a line of successive panels must be removed to
remove an individual panel downstream that is in need of repair.
For example, panel repair for a progressive removable panel system
would require removal of the drywall to the framing studs,
installation of new drywall, as many as three coats of compound
with interim sanding and a final step of painting. Since matching
existing paint is difficult, entire walls are often repainted.
Bypassing the added expenses of repairing damaged progressive
removable panels, the removable wall panel system of the presently
disclosed embodiments provides for instant repair of any panel
damaged in the system without removing adjacent panels. The wall
panel system of the presently disclosed embodiments provides a
removable wall panel system that permits removal of individual
panels without affecting adjacent panels and does not require
progressive panel removal. Thus, the wall panel system is useful
for easier and quicker panel repair and panel replacement.
[0070] A method for mounting a wall panel to an existing structure
includes installing at least one wall mount, wherein the wall mount
may be shimmed as required to keep the wall mount level; installing
at least one mounting member, wherein the mounting member is
secured to a back side of the panel, wherein the mounting member is
secured to the back side of the panel in at least one pre-drilled
pilot hole; engaging each mounting member to each wall mount. In an
embodiment, the method for mounting a wall panel includes
installing additional end members and corner members as needed.
[0071] A method for mounting a wall panel system to an existing
structure includes installing at least one wall mount, wherein the
wall mount may be shimmed as required to keep the wall mount level;
installing at least one mounting member, wherein the mounting
member is secured to a back side of the panel, wherein the mounting
member is secured to the back side of the panel in at least one
pre-drilled pilot hole; engaging each mounting member to each wall
mount; repeating installation of the wall mounts and the mounting
members as many times as necessary to add as many panels are
necessary to complete requirements for a particular
installation.
[0072] A method for removing a panel includes disengaging a panel
from an existing structure, wherein disengagement of the panel
comprises disengaging at least one mounting member of the panel
from at least one wall mount, wherein upon disengagement of each
mounting member of the panel from the wall mount a panel is capable
of being removed, wherein upon disengagement of each mounting
member, each mounting member remains secured to the panel and each
wall mount remains secured to the wall; and removing the disengaged
panel from the existing structure.
[0073] A method of replacing at least one panel includes providing
one high impact, moisture resistant panel to replace each removed
panel, wherein each panel has a front face and a back face; and
providing at least one mounting member having a first end and a
second end, wherein the first end of the mounting member is secured
to the back face of the panel; and engaging the second end of each
mounting member with the second end of each wall existing wall
mount residing on the existing structure, wherein engagement of the
mounting member with the wall mount secures the panel to the
existing structure in a substantially parallel manner.
[0074] A method for configuring at least one panel to form a high
impact, moisture resistant wall panel system includes providing at
least one panel for each panel being removed, and providing a wall
mount, wherein the wall mount is installed in horizontal
orientation across a wall span beginning at a first end and
continuing to a second end, wherein the wall mount may be installed
between a ceiling and the panel or the wall mount may be installed
between a base and the panel or the wall mount may be installed
between adjacent panels, wherein the wall mount forms a continuous
horizontal reveal beginning at the first end and continuing to the
second end; and providing a vertical reveal, wherein the vertical
reveal intersects with the horizontal reveal in at least one joint
between adjacent panels, and wherein the vertical reveal is
integrated with the horizontal reveal; and engaging the second end
of each mounting member with the second end of each wall mount,
wherein engagement of the mounting member with the wall mount
secures the panel to the existing structure in a substantially
parallel manner.
[0075] FIG. 6 shows a top cross-sectional view of a vertical joint
and adjacent panels. In an embodiment, the joint is an expansion
joint. As shown in FIG. 6, each panel 30 is placed adjacent each
other with sufficient space between the panels to form a vertical
reveal 44 between the panels. Each panel 30 has a mounting member
38 approximately near the undercut 28 edge of each panel 30 that
engages a wall mount 40 that is secured to the existing structure
16.
[0076] In an embodiment, the wall mount 40 spans across the
horizontal length of the wall panel system forming a horizontal
reveal 46 (as shown in FIG. 7) between two adjacent panels
side-by-side stacked one above the other. In an embodiment, the
vertical reveal 44 abuts each panel approximately near and
approximately along the undercut edge 28. In an embodiment, the
vertical reveal overlays the wall mount 40 and is secured to the
wall mount with at least one screw 48. The wall mount 40 is secured
to the existing structure 16 with a at least one screw (as shown in
FIG. 7). In an embodiment, at least one shim 42 is used to ensure
that the panels secured to the existing structure are plumb and
level. In an embodiment, no shim is used to keep the panels level
and plumb.
[0077] A screw 48 of the presently disclosed embodiments includes,
but is not limited to a self-tapping screw, a self-drilling screw,
a self-tapping pan screw, a self-drilling pan screw, a zinc plated
self-tapping pan screw, a zinc-plated self-drilling pan screw, a
dry-wall screw, or a sheet metal screw.
[0078] FIG. 7 shows a side cross-sectional view of a horizontal
joint and adjacent panels stacked one above another in vertical
orientation. In an embodiment, the joint is an expansion joint. As
shown in FIG. 7, each panel 30 is placed adjacent each other with
sufficient space between the panels to form a horizontal reveal 46
between the panels. Each panel 30 has a mounting member 38
approximately near the undercut 28 edge of each panel that mates
with a wall mount 40 that is secured to the existing structure with
at least one screw 48.
[0079] The horizontal reveal 46 integrates seamlessly with the wall
mount 40 to form a wall mounting system. In an embodiment, the wall
mounting system comprises extrusions. In an embodiment, the wall
mounting system is aluminum. In an embodiment, the wall mounting
system is an aluminum extrusion. In an embodiment, the wall
mounting system integrates seamlessly with the horizontal reveal 46
and spans across the full horizontal length of the wall panel
system. In an embodiment, at least one shim 42 may be placed
between the wall mount 40 and the existing structure 16 to ensure a
level and plumb installation of the wall panel system. In an
embodiment, no shim is used to keep the panels level and plumb.
[0080] In an embodiment, a means for securing a panel to the
existing structure is provided comprising a mounting member 38, a
wall mount 40, and at least one screw 48. Any means for securing
the panel to the existing structure will suffice. In an embodiment,
the means for securing comprises a mounting clip. In an embodiment,
the means for securing comprises a z-clip. In an embodiment, the
means for securing comprises a two inch wide mounting clip that is
twenty-four inches on center. Those skilled in the art will
recognize that other mounting systems known in the art may be used
within the spirit and scope of the presently disclosed
embodiments.
[0081] FIG. 8 shows side cross-sectional view of a horizontal joint
between a panel 30 and a ceiling 19. In an embodiment, the joint is
an expansion joint. As shown in FIG. 8, a panel 30 is placed
adjacent the ceiling leaving sufficient space between the panel and
the ceiling to form a horizontal reveal 46 in between the panel and
the ceiling 19. The horizontal reveal 46 may have any thickness. In
an embodiment, the horizontal reveal approximates to 3/8 inch
thick. Each panel 30 has a mounting member 38 approximately near
the undercut 28 edge of each panel that engages a wall mount 40
that is secured to the existing structure with at least one screw
48. In an embodiment, the horizontal reveal 46 is integrated
seamlessly with the wall mount and spans across the full horizontal
length of the wall panel system. In an embodiment, the horizontal
reveal 46 approximately fills the space between the ceiling 19 and
the undercut edge 28 of the panel 30. In an embodiment, the
horizontal reveal fills the space between the ceiling and the
undercut edge of the panel. In an embodiment, the horizontal reveal
abuts the ceiling and approximately fills the space near the
undercut edge. In an embodiment, at least one shim 42 between the
wall mount 40 and the existing structure 16 ensures a level and
plumb installation of the wall panel system. In an embodiment, no
shim is used to keep the panels level and plumb. In an embodiment,
at least one screw 48 secures the wall mount to the existing
structure.
[0082] FIG. 9 shows a side cross-sectional view of a bottom panel
30 near a base 18. In an embodiment, the base 18 is a stainless
steel base. In an embodiment, the base 18 comprises a panel cut to
fit between a panel and the floor 15. In an embodiment, the base 18
is designed to match its surrounding environment. As shown in FIG.
9, a base 18 is attached to the existing structure 16 and
approximately fills the space near the undercut edge 28 of the
panel. In an embodiment, the base fills the space near the undercut
edge of the panel. Each panel 30 is secured to the existing
structure 16 with a mounting system comprising a mounting member 38
that is secured to the panel on one end, wherein the mounting
member 38 engages a wall mount 40 on the other end. Engagement
between the mounting member and the wall mount forms a secure,
flexible lock that provides for stable, yet removable panels. The
wall mount is secured to the existing structure with at least one
screw 48.
[0083] In an embodiment, a means for connecting a panel to an
existing structure is provided comprising a mounting system. The
mounting system further comprises at least one screw and at least
one clip. In an embodiment, the mounting system comprises a
mounting member 38 and a wall mount 40. In an embodiment, the
mounting system comprises at least one screw 48. In an embodiment,
the mounting system uses a shim 42 to keep the panel plumb and
level with respect to the existing structure. In an embodiment, no
shim is used to keep the panels level and plumb.
[0084] FIG. 10 shows a top cross-sectional view of an inside corner
joint between two adjacent corner panels. In an embodiment, the
joint is an expansion joint. As shown in FIG. 10, each panel 30
abuts a central corner member 50 leaving sufficient space between
each panel to form a vertical reveal 44 (as shown in FIG. 6). The
vertical reveal 44 may have any thickness. In an embodiment, the
vertical reveal is about 3/8 inch wide. At least one screw 48
secures the corner member to the existing structure 16. In an
embodiment, the corner member 50 is an inside corner guard. In an
embodiment, the corner member 50 is an inside corner molding. In an
embodiment, the corner member 50 is an inside corner trim. In an
embodiment, the corner member 50 is an inside corner connector. In
an embodiment, at least one shim 42 is placed between the corner
member 50 and the existing structure 16 to maintain level panels.
In an embodiment, no shim is used to keep the panels level and
plumb. In an embodiment, the corner member 50 abuts each panel 30
along the undercut edge 28. In an embodiment, the corner member 50
approximately fills the space near the undercut edge 28. In an
embodiment, there is an axis of symmetry parallel to the beveled
edges 32 of each panel 30.
[0085] A mounting member 38 is affixed to each panel 30
approximately near the undercut edge 28 of the panel. In an
embodiment, the mounting member engages a wall mount 40 which in
turn is secured to the existing structure 16 with at least one
screw 48. In an embodiment, at least one shim 42 is used to ensure
that the panels are level and plumb with the existing structure. In
an embodiment, no shim is used to keep the panels level and
plumb.
[0086] FIG. 11 shows a top cross-sectional view of a panel at an
end of the wall panel system. As shown in FIG. 11, an end member 52
is secured to the existing structure 16 with at least one screw 48.
The end member 52 abuts against the undercut edge 28 of the panel
30. In an embodiment, the end member 52 approximately fills the
space near the undercut edge. In an embodiment, the end member
fills the space between the undercut edge and the existing
structure. In an embodiment, a mounting member 38 is affixed
approximately near the undercut edge 28 of each panel 30. The
mounting member 38 engages a wall mount 40 which is secured to the
existing structure 16 with at least one screw 48.
[0087] FIG. 12 shows a top cross-sectional view of an outside
corner joint between adjacent corner panels. In an embodiment, the
joint is an expansion joint. As shown in FIG. 12, each panel 30
abuts a corner member 54 approximately near the undercut edge 28 of
each panel leaving sufficient space between the panels to form a
vertical reveal 44. The vertical reveal 44 may have any thickness.
In an embodiment, the vertical reveal is about 3/8 inch wide. The
corner member is secured to the existing structure with at least
one screw 48. In an embodiment, the corner member 54 fills the
space near the undercut edge 28 of each panel 30. In an embodiment,
the corner member 54 approximately fills the space near the
undercut edge 28 of each panel 30. In an embodiment, the corner
member 54 is an outside corner guard. In an embodiment, the corner
member 54 is an outside corner molding. In an embodiment, the
corner member 54 is an outside corner trim. In an embodiment, the
corner member 54 is an outside corner connector. In an embodiment,
a at least one shim 42 is placed between the corner member 54 and
the existing structure 16 to maintain level panels. In an
embodiment, no shim is used to keep the panels level.
[0088] Each panel 30 is secured to the existing structure 16 by
engaging a mounting member 38 with a wall mount 40 to form a
secure, flexible lock that provides removable panels. In an
embodiment, at least one shim 42 is placed between the wall mount
40 and the existing structure to ensure a level panel installation.
In an embodiment, no shim is used to keep the panels level.
[0089] The wall panel system also contemplates moldings that may be
adapted to the needs of a particular job design. Provisions for
making and adapting moldings to panel systems are known in the art.
Moldings may be extruded from the same polymer composition used to
form the laminate sheets and are preferably formed from polyvinyl
chloride, to which a proportionately smaller amount of acrylic is
added. Those skilled in the art will recognize other moldings that
may be adapted for use in the presently disclosed embodiments.
[0090] The removable high impact, moisture resistant panels of the
presently disclosed embodiments have been tested for and are in
compliance with international standards including, but not limited
to ASTM E 84-07 for fire performance.
[0091] A panel of the presently disclosed embodiments has a Class A
Flame Spread Index/Smoke Developed Index per ASTM E84-07/UL723.
ASTM E84-07/UL723 determines the surface burning characteristics of
the material, specifically the flame spread and smoke developed
indices when exposed to fire. The maximum distance the flame
travels along the length of the sample from the end of the igniting
flame is determined. Test results are shown in Table 1.
TABLE-US-00001 TABLE 1 ASTM E84-07/UL723 Flame Spread Test Results
Calculated Smoke Calculated Flame Spread Smoke Developed Test
Sample Flame Spread Index Developed Index White Panel 10.58 10
352.6 350
[0092] All patents, patent applications, and published references
cited herein are hereby incorporated by reference in their
entirety. It will be appreciated that several of the
above-disclosed and other features and functions, or alternatives
thereof, may be desirably combined into many other different
systems or applications. Various presently unforeseen or
unanticipated alternatives, modifications, variations, or
improvements therein may be subsequently made by those skilled in
the art which are also intended to be encompassed by the following
claims.
* * * * *